Modular green roof system, apparatus and methods, including interconnecting modular panels

ABSTRACT

A modular green roof system includes modular panels ( 10 ) providing a surrounded space suitable for supporting live plant growth and adapted for installing onto a roof deck in side-by-side positioning while allowing water flow on the roof thereunder. The panels are installed with growing medium and greenery, and are releasably connected in a non-progressive manner that permits removal of a surrounded panel without disturbing the adjacent panels. The panels are further adapted to be pre-seeded prior to delivery to the roof site, and delivered in either a preserved condition or a germinated condition; and are adapted for connection to an edge finishing/edge termination system ( 46 ) and support structure to enable provision of non-panel areas of the green roof, and above-panel structures.

CROSS-REFERENCES TO RELATED APPLICATIONS

This application claims the benefit of U.S. Provisional PatentApplications Ser. No. 60/218,889 filed Jul. 18, 2000, Ser. No.60/219,063 filed Jul. 18, 2000, and Ser. No. 60/219,457 filed Jul. 18,2000.

REFERENCE TO MICROFICHE APPENDIX

not applicable.

STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT

not applicable.

TECHNICAL FIELD

The present invention relates generally to green roof systems, alsoknown as roof landscaping systems and roof gardens, that are suitablefor supporting live plant growth on building roofs.

More particularly, the invention relates to modular green roof systems,and methods and apparatus for use therewith.

BACKGROUND OF THE INVENTION

Briefly, prior green roof systems typically comprise several layers ofmaterials suitable to support vegetation on a roof. These layers aretypically supplied in bulk or earthen rolls that are rolled intoposition on the roof.

Common types of vegetation used in green roof systems include herbs,grasses, mosses, wild plants and flowers, and other types of perennials.

A typical prior green roof system includes at least (i) a waterproofingmembrane laid over the roof or roof supporting structure, (ii) based onthe roof grade, a layer over the waterproofing membrane of one of: (a) adrainage layer and an overlaying blanket of root growth protectionmaterial (for a grade of approximately 2 to 5 degrees), (b) a rootgrowth protective fleece (for a grade of approximately 6 to 10 degrees),and (c) a substrate fixing or erosion control blanket including rootgrowth protection (for a grade of approximately 10 to 20 degrees); (iii)a layer of mineral wool or other substrate for water retention, and (iv)a top layer of vegetation growing in a fiber fleece or other suitablegrowing medium.

Other green roof designs include additional layers of various materialsfor various roof protection and vegetation growth support purposes.

It is believed that prior green roof systems of the above general typewere first used in Europe approximately 20 years ago. Since that time,use of similar and derivative green roof systems has become common inmany parts of Europe on commercial, institutional, industrial, andresidential buildings, and interest in green roof systems is growing inthe United States.

The advantages typically attributed to green roof systems includeextending the roof service life; reducing heating and cooling energycosts; conserving and utilizing valuable commercial space; reducingrunoff from roof surfaces; and increasing property values.

However, inspection of such prior systems also reveal the followingdisadvantages:

-   -   the prior systems are relatively expensive and are difficult to        install, typically requiring the need for and assistance of a        specially trained consultant;    -   the systems are not designed to be installed over an existing        functional roof without the necessity of reroofing;    -   thus, a complete new waterproofing membrane must typically be        installed before the green roof system can be used on existing        buildings, resulting in additional costs;    -   since the green roof materials are delivered in bulk or earthen        rolls, design freedom is limited, alternating designs of plants        are not easily incorporated in the design of the green roof;    -   terracing or variations of surfaces are also not easily        accomplished; and changing of the design layout after        installation requires removal and destruction of the effected        area and replanting with the new design;    -   selection of pre-growing plants in the upper fiber fleece is        typically limited to low-growing plants, mosses, etc., since the        fleece is supplied to the roof in rolls;    -   selection of pre-grown plants available is further typically        limited because: the need to maintain the plants in the growing        state prior to shipment results in additional costs; the demand        must be estimated in advance of the installation season in order        to have the pre-grown plants ready; and such estimates are        typically conservative in order to prevent overstocking and        spoilage if not used during that season; and    -   maintenance and repair to the roof is difficult and expensive;        if a leak develops in the roof membrane, or if other maintenance        or repair is required, the entire green roof, or at least large        portions of the green roof, must be removed to locate and repair        the leak or accomplish the desired maintenance; the removed        green roof must then be replaced and replanted.

Thus, it is clear there is a need for new and improved green roofsystems which:

-   -   are less expensive and more easily installed than prior green        roof systems;    -   can be installed over existing roofing materials on existing        buildings, thus eliminating the need and associated cost to        install completely new roofing membranes or systems prior to        installation of the green roof;    -   provide for substantially enhanced design flexibility and        freedom, including;        -   the ability to change the design layout of the green roof            after initial installation, and        -   the ability to be used either as a standalone system, or in            combination with prior green roof systems            -   as an original green roof layout and design including                both prior systems and systems in accordance with the                present invention, and            -   to enable repair of a prior green roof such as when a                portion of the prior green roof has been removed for                repairs of the building roof deck, to eliminate the                current need to re-install the entire prior green roof                systems after such removals or repairs; and    -   permit ease of access to desired portions of the roof for        maintenance and repair without the need to destroy and then        replace large portions of the green roof.

SUMMARY OF THE INVENTION

The general aim of the present invention is to provide new and improvedgreen roof systems, and methods and apparatus therefore—to address theabove-identified disadvantages of prior green roof systems and achievethe advantages and benefits flowing from addressing the above-identifiedneeds thereof.

More particularly, it is an objective of the invention to provide amodular green roof system comprising interconnecting modular panelshaving a surrounded space suitable for supporting live plant growth andadapted for installing onto an existing roof deck in side-by-sidepositioning while allowing water flow on the roof thereunder. The panelsare installed with growing medium and greenery, and are releasablyconnected in a non-progressive manner that permits removal of asurrounded panel without disturbing the adjacent panels, thus providingfor ease of repair of the roof structure by simply removing thenecessary panels. The panels are adapted to be pre-seeded prior todelivery to the roof site, and delivered in either a preserved conditionor a germinated condition. In preferred embodiments, the panels are alsoprovided with a interconnecting watering apparatus to assist insupporting the growing plants therein. The panels are further adaptedfor, and associated apparatus and methods are provided for, connectionto an edge finishing/edge termination system and a support structure, toenable provision of non-panel areas of the green roof, and above-panelstructures including structures adapted to assist in lifting andpositioning into place on the roof, or removing from the roof, withoutdisturbing adjacent panels.

Consequently, the interconnecting modular panels of the invention aremore easily installed than prior green roof systems, and the panels moreeasily lifted and the roof structure repaired without the need todestroy a substantial portion of the installed green roof as with priorgreen roof systems. The modular panels enhance design-layout flexibilityby enabling provision of a greater selection of growing and non-growingmaterials for the green roof system without concern for spoilage,enabling the growing materials to include those requiring greater soildepth than is available in prior green roof systems, and enabling thepanels to be rearranged after installed. These aspects allow thedesigner or architect to select a broad variety of various colored orheight plants to be incorporated within the system. In addition, thepanels can be filled with proper growing soil composition for optimalgrowth potential for each pre-planted species, the panels can bealternately filled with any desired or decorative material such asgravel or concrete for walkways, and the filled panels can be used toachieve a desired weight for desired ballast required for loose-laidmembrane roof such as of at least approximately 10-12 lb./sq. ft.

In combination with the edge termination/edge finishing system andsupport structure, the panels enable provision of multi-level terracingof the green roof, provision of bounded areas for uses such as a waterpond, a field planted area, walkway areas, and putting greens, provisionof above-panel structures, and other elements to the designer'simagination.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a top diagrammatic view of a modular green roof system inaccordance with and incorporating the unique aspects of the presentinvention.

FIG. 2 is a perspective view of a green roof system includingmulti-level terracing.

FIG. 3 is perspective view of a modular panel incorporating certainunique aspects of the invention, and suitable for use in a modular greenroof system according to the invention.

FIG. 4 is a side view of the panel of FIG. 3 and showing the panelpre-seeded in accordance with the invention.

FIG. 5 is fragmentary top view taken substantially along the line 5-5 ofFIG. 4.

FIG. 6 is fragmentary view taken substantially along the line 6-6 ofFIG. 4.

FIGS. 7A and 7B are fragmentary view showing adjacent modular panelsconnected together as installed on a roof with alternateclosure/connector strips.

FIGS. 8 and 9 are views similar to FIG. 7 but showing alternateapparatus connecting the adjacent panels.

FIG. 10 is a view similar to FIG. 7 but showing a water line and riserof an installed watering system.

FIG. 11 is a top view of the panel flanges of FIG. 10 but showing theflanges separated for illustrative purposes.

FIG. 12 is a view similar to FIG. 11 but showing the watering systemcomponents as installed in connection with the alternate panel connectorof FIG. 8.

FIG. 13 is a fragmentary perspective view of an alternate panelincorporating integral provisions for a watering system.

FIG. 14 is an enlarge fragmentary view of a panel edge system inaccordance with another aspect of the invention.

FIG. 15 is a fragmentary cross-sectional view showing constructiondetails of one embodiment of a non-modular area of the green roof, andmore particularly, showing a pond area such as generally indicated inFIG. 1.

FIGS. 16 and 17 are top and side fragmentary views, respectively, of asupport connected to the modular panels/edge system framework andadapted to support an above-roof framework.

FIG. 18 is a fragmentary side view showing a walkway supported by thepanel edge system to provide access to planted areas of the green roof.

FIG. 19 is a side view of edge termination system suitable formulti-level terracing as generally shown in FIG. 2.

FIG. 20 is a perspective view of a panel and cables adapted to assist inraising and lowering the panel from the roof.

FIG. 21 is an enlarged fragmentary view of the panel and cable shown inFIG. 20.

FIG. 22 is a perspective view of an installed green roof and showing apanel being lifted from a predetermined location on the roof deckwithout disturbing previously installed panels surrounding and adjacentto the predetermined location.

FIG. 23 is a perspective view of an above-roof temporary frameworkadapted for assisting in installation, removal and moving of filledpanels.

FIGS. 24 and 25 are side views of alternate frameworks suitable forassisting is installation, removal and moving of filled panels.

FIG. 26 is a perspective view of an alternate aboveground structuresupported be the framework of the green roof system.

FIG. 27 is a view similar to FIG. 26 of an alternate above-groundstructure in the form of a walkway.

FIG. 28 is a view similar to FIG. 15 of an alternate bounded non-modulararea of the green roof system.

FIG. 29 is an enlarged side view illustrating certain aspects ofpre-seeding, preserving and shipping of modular panels.

FIG. 30 in an enlarged fragmentary side view illustrating certainaspects of shipping panels with larger pre-growing plants.

FIG. 31 is a view of a panel provided with alternate flexible,interconnectable, drip-irrigation lines which may be used for bothpre-growing prior to delivery to the roof site, and which may beinterconnected connected at the roof site.

While the invention is susceptible of various modifications andalternative constructions, certain illustrated embodiments have beenshown in the drawings and will be described below in detail. It shouldbe understood, however, that there is no intention to limit theinvention to the specific forms disclosed, but on the contrary, theintention is to cover all modifications, alternative constructions, andequivalents falling within the spirit and scope of the invention.

BEST MODE FOR CARRYING OUT THE INVENTION

Brief Description of Modular-Design Green Roof System

The present invention relates to a modular-design green roof system thatis uniquely adapted to provide versatility of design with a broad rangeof design layout possibilities, while simultaneous providing for ease ofinstallation and maintenance, and repairs to both the green roof and theunderlying roof structure or roof deck of the building on which thegreen roof is installed.

Green roof systems of the present invention include interconnectingmodular pans or containers herein generally referred to as “panels”adapted to provide both green and non-green areas on the roof deck, andcertain associated apparatus, for ease of maintenance and repair of theunderlying roofing structure and replacement of the modular panels, andto provide for design freedom and ease of installation, maintenance andrepairs. Preferred systems include pre-seeded panels to provideadditional design flexibility, and apparatus for edge termination fordefining the boundaries of the green roof areas provided by the modularpanels and optionally providing bounded non-green roof areas such as forponds, walkways, putting greens and other desired structures or uses.

Briefly, filled panels are arranged on a roof deck in a desiredaesthetic design layout such as illustrated in FIG. 1 in which thenumbers associated with each panel 10 represent characteristics of thepanels and/or the green roof-panel fill materials.

The panels can be of different heights and depths, and planted withvarious sedum, foliage, or perennials to provide for various “green”areas for a desired visual effect. Alternately, and in addition, thepanels can be filled with decorative and/or functional materials such asgravel, decorative rocks, mulch or other materials to provide for“non-green” areas.

In accordance with the invention, the panels are interlocking withadjacent panels in a non-progressive manner, to provide a stable, andwind resistant green roof, while simultaneously providing for ease ofmaintenance and repair of the underlying roofing structure and for easeof replacement of the modular panels. In preferred embodiments, thepanels are pre-filled and pre-planted, i.e., pre-seeded, such that thepairs of numbers associated with each panel shown in FIG. 1 mayrepresent, for example, the (i) height of the panel and (ii) the typeand/or color of plant in the panel. This provides substantial designfreedom and ease of layout design from a selection of pre-plantedpre-designed modular units. Preferred panels are also adapted forconnection to an edge termination system adapted to define theboundaries of the green roof areas provided by the modular panels, andoptionally providing bounded non-green (non-growing) roof areas such asfor ponds, walkways, putting greens and other desired structures oruses.

Design versatility of the present invention is further illustrated inFIG. 1 wherein the green roof includes a ponded area 12, and in themulti-level green roof embodiment shown at 14 in FIG. 2, both of whichare discussed further below.

Modular Panels

In accordance with one aspect of the invention, modular panels areprovided that are adapted for filling with a growing medium andsupporting plant life, and are suitable for placing directly onto a roofdeck in a modular green roof system.

As discussed further below, the panels optionally include a cover, orare configured for accepting a cover, and/or for temporarily connectingtogether for storage and transportation of pre-filled panels prior toinstallation, and/or for temporary storage and stacking during repairsto the roof.

One embodiment of a modular panel suitable for use in accordance withthe present invention is the panel 10 shown in detail in FIGS. 3 and 4.

In this instance, the panel 10 is vacuum formed, molded or otherwiseshaped modular panel made from high-strength plastic, HDPE (high densitypolyethylene), recycled rubber or any moldable material suitable toachieve cost effective manufacture, sufficient strength and rigidity forthe panel size, and a desired durability and long life.

The panels are formed in modular sizes convenient for handling such asbetween approximately one and one-half to eight inches deep, and up to16 square feet surface area, or otherwise as desired. One convenientsize for certain roofs and greenery, and for manual handling is a panmeasuring approximately 2 feet by 4 feet. The preferred shape of thepanels is generally rectangular so that the panels cooperate with eachother and/or additional apparatus discussed below, to generally coverthe roof when viewed from above.

The sides 16 and bottom 18 of the panel 10 shown are formed withreinforcing ribs 20 (see FIGS. 5 and 6) to achieve additional strengthand rigidity for a given wall thickness.

A waffle design on the under side of the bottom 18, such as defined bycrisscrossing ribs or flow passages 22 extending along the underside ofthe panel, or other downwardly facing voids, for lowered feet portions(not shown) to raise the floor of the panel above the roof, allowmulti-directional free water flow and drainage on the roof deck underthe panel.

Drain holes 24 formed through the bottom 18 of the panel 10 providewater drainage of soil mass or other contents in the panel. The size andnumber of drain holes in this area can be varied to provide the idealamount of moisture content for the various types of plants and soil

Drain ports or holes 24A formed in the sides of the panels 10 are placedto assure run off therethrough in the event the water level in the panelrises to the height of these holes, thereby providing a control for thetotal weight of the panels during periods of excessive rainfall.

Optional grooves 25 are formed along the bottom of the panel 10 toassist in installation and removal of filled panels as discussed furtherbelow.

The sides 16 of the panel 10 are preferably tapered to allow for ease ofremoval from the vacuum mold, and for additional reasons discussedbelow, are preferably sized for clearance in the neighborhood of betweenapproximately 1 to 2 inches between sides of adjacent panels when inside-by-side relation.

Flanges 26 may be formed in a desired configuration along the upper edgeportions of the panel 10 for cooperation with adjacent panels, and/orconnecting and termination arrangements discussed below. Advantageously,flanges provide the panel with additional stiffness, to assist inmaintaining the panel shape when moving filled panels.

A webbing or netting 28 is placed on the bottom of the panel 10 prior tofilling with the growing medium to prevent root growth into and throughthe drain holes 24 and onto the roof deck below the panel.

As will be apparent, alternate modular panel embodiments, adapted forfilling with either a decorative fill, or a growing medium and plantlife, and including alternate construction and flange or edge details,are also suitable for use in the green roof system of the presentinvention as contemplated herein.

Accordingly, a green roof system can be quickly and easily installedwith the use of such modular panels by covering the roof, or the desiredportion of the roof, with panels in side by side or abutting relation,the panels being filled with desired growing and non-growing green roofmaterials.

Advantageously, the larger, heavier filled panels provide the ballastthat is necessary for a conventional loose-laid membrane roof in amodular manner to permit ease of removal for inspection of and repair tothe membrane.

Interconnecting Modular Panels

In carrying out the invention, the modular panels are provided forreleasably connecting together. Such an arrangement is useful inproviding a cohesive, wind resistant, non-shiftable green roof system,and is particularly useful in connection with shallow, relatively lightpanels to prevent high wind from lifting the panels from the roof deck.

In carrying out this aspect of the invention, in the embodiments shown,apparatus is provided for releasably connecting the flanges of adjacentpanels together. Alternately, for example, for panels without flanges,the sides of adjacent panels may be connected directly together.

One embodiment of panel/flange connector is shown in the drawings inFIG. 7A as a closure strip 32 in the form of an elongated, extrudedplastic or aluminum strip comprising an outer face 34 sized to overlapthe outer edge portions of the flanges 26 of adjacent panels, and a pairof laterally spaced leg portions 36 and associated bent knee portions 38extending downwardly from the outer face 34 and cooperating to cover orseal off the void between the adjacent panels. An alternate closurestrip 32B shown in FIG. 7B is provided with sharp prongs that areinserted through the flanges of adjacent panels to connected the panelstogether.

In an alternate embodiment shown in FIG. 8, adjacent panels areconnected with a closure strip 40 such as a molded plastic or treatedwood strip, and suitable fasteners such as the butterfly type threadedfastener 42 to secure the flanges 26 of the adjacent panels to theclosure strip.

A second alternate connector is shown in FIG. 9 connecting modifiedflanges 26A. In this instance, the adjacent flat flanges are positionedoverlapping one another, and are connected with fasteners such threadedscrews 44. As discussed further below, in the event of connecting theflanges in an overlapping manner, the flanges are preferably relativelyflexible or resilient such that the panel with the flange under theother may be removed from the roof without the need to remove the panelhaving the flange on top.

Persons skilled in the art will appreciate alternate connectors orfasteners may be used for releasably connecting adjacent panelstogether, with the edge details or flanges of the panels being modifiedfor use therewith. By way of non-limiting examples, in alternateembodiments not shown, the panels are provided with releasable,snap-together interlocking flanges for connecting adjacent panels,apparatus is provided for connecting parts of adjacent panels other thanwith the flanges or upper edges of the panels, or holes are provided inthe adjacent panels for the use of cable ties and other flexibleconnectors to tie the panels together.

Watering System

To provide for ease of maintenance of the green roof system, the panelsare preferably provided with interconnecting watering apparatusconnected to one or more water supply lines. Conveniently, a watersupply line 64 is optionally provided, running in the approximately 1 to2 inch clearance provided between adjacent tapered panels such as shownin FIGS. 10 and 12, with pressurized irrigation risers 66 extendingupwardly through the overlapped flanges 26A of the adjacent panels, or,for example, through the closure strip 40 (FIG. 12) for periodicwatering of the plant life in the green roof system. In this instance,one or both of the overlapping flanges 26A are notched (such as shown inFIG. 11 wherein the flanges are shown separated for illustrativepurposes) for the riser to extend therethrough.

Advantageously, such internal watering arrangements provide additionaldesign freedom since they are easily adapted for use with specific greenroof design layouts, such as with the alternate edge systems.

An alternate panel 160 molded with integral water line and riserreceiving locations is shown in FIG. 13. In this instance, the panel ismolded with a pop-out opening 166 sized to receive the riser or standardsprinkler head 168 which is then connected to a T-connector 170 forjoining with water line hoses 164 running in cylindrical or curvedindentations 162 molded in the sides of the panel.

In another alternate embodiment shown in FIG. 31, the panels areprovided with flexible, interconnectable, drip-irrigation lines.

Edge Finishing/Green Roof Termination System

In accordance with yet another aspect of the invention, the panels areadapted for use with edge finishing/edge termination systems areprovided for connecting to and/or cooperating with the panels to definethe various boundaries of the green roof system. Such edge finishing isadapted for decorative effect at the boundaries, and/or for functionalpurposes including supporting the flanges or panels, or connectionbetween the panels and/or other structures as discussed further below.Briefly, the edge finishing is of a suitable, durable, decorative and/orstructural material and configuration for cooperation with the modularpanels to define the boundaries of the green roof system.

In carrying out this aspect of the invention, in the embodiments shown,termination detail is provided in the form of an edge finishing—facingmaterial adapted for connection to the flanges of the panels.

In the preferred embodiments shown in the drawings, dimensional lumberor composite extruded or other material beam is provided for thetermination/facing material to define the boundaries of the green roofsystem. Such boundaries include outer boundaries, inner boundaries ofenclosed areas, and transition boundaries of the green roof system. FIG.14 illustrates one embodiment of termination or edge detail using afacing material in the form of a structural beam, dimensional lumber orcomposite extrusion 46 to finish off the exposed edges of panels locatedalong the boundaries of the green roof system. In this instance, thedimensional lumber or composite extrusion 46 is standing on its loweredge on the roof (not shown), and is located under, shaped for, andconnected to the flange 26 for positioning and support thereof. As shownin FIGS. 17 and 18, alternate flange-supporting and/or edge systems willbe adapted for the specific flange configuration with which they areconnected to and/or used with.

Persons skilled in the art will also appreciate that alternate edgefinishing/edge termination systems will be provided within the scope ofthe present invention. By way of non-limiting example, in an alternateembodiment not shown, the outer and inner boundaries of the green roofsystem are defined by decorative facing material shaped for slippingover the flanges or exposed edges of the modular panels, the facingbeing sized to extend downwardly to the roof deck.

Multi-level Green Roof

As previously mentioned and shown in FIG. 2, the present inventioncontemplates a green roof capable of multi-level terracing. This isaccomplished with the use of panels of different depths andintermediate, boundary transition edge finishing systems therebetween.

Advantageously, the ability of the system to accommodate the use ofpanels of different height also permits the growth of various plantedmaterial which may not be suitable for growth in prior green roofsystems. In particular, the modular panels and associated apparatus ofthe present invention enable, for example, provision of plants requiringare substantial depth of soil or other growth medium.

In carrying out this aspect of the invention, interconnecting, boundarytermination facing material such as described above comprises suitableheight transition apparatus and accommodates multi-level terracing in avisually appealing manner.

In particular, one method of transitioning between panels of differentheights with the dimensional lumber/composite extrusion edge systemdescribed above is shown in detail in FIG. 19. In this instance, theedge pieces 46A and 46B are secured under associated flanges 26A ofadjacent panels of different heights, and are tied together with nails48. Block 50 is optionally provided for additional lateral support atthe base of the edge termination pieces.

In an alternate embodiment edge system, a facing material is connectedbetween the flanges of the adjacent panels of different height to coverthe exposed side portions of the taller panel.

Additional Modular Components and Bounded Areas

The present invention also contemplates and accommodates additionalmodular components and bounded areas

-   -   providing for additional design freedom and flexibility. The        following are illustrative of a few such additional components        and bounded areas, and edge finishing/edge termination systems        associated therewith.

Alternate Decorative or Functional Fills

As previously mentioned, the modular panels 10 may be filled withdecorative gravel, concrete or other non-green materials for decorativepurposes, or functional purposes such as to provide walkways through thegreen roof.

For example, in one embodiment, a walkway is provided with panels of aheight less than the surrounding panels filled with, for example,growing greenery, with suitable edge support and edge finishing orheight transition system provided such as previously described, and/oras illustrated in FIG. 18.

In an alternate embodiment, the walkway is provided in panels of thesame height as surrounding panels, but which may be partially filledwith a light-weight “filler” under the walkway material to reduce theweight of the filled panel if desired.

Pond Area

Additional design flexibility is available through the unique ability ofgreen roof systems of the invention to include ponded areas such asindicated in FIG. 1 with the use of an internal boundary edge finishingsystem.

The details of one embodiment of a pond area 52 is shown in FIG. 15. Inthis instance, the water is contained in a loose-laid membrane 54, suchas made from flexible EPDM, that is surrounded by panel terminationdimensional lumber/composite extrusion 46 and is secured between theflanges 26 and the lumber/extrusion; with wooden strip 58 provided foradditional lateral support. To insure positive omni-directional drainageon the roof deck, the membrane is laid over a grid work of material suchas round river rock 56, to allow drainage under the membrane. Such anarrangement may be adapted for a permanent ponded area purely foraesthetic purposes when provided with a water supply and associatedapparatus, or alternately for a collection area for natural rain water,such as to be optionally re-used in watering the green roof system.

Other Non-modular Areas

Use of the edge termination system with the panels 10 to create othernon-modular areas of the roof deck provides yet additional flexibilityin the design of the green roof system.

For example, in an alternate arrangement shown in FIG. 28, anedge-termination/membrane-enclosed area similar to the ponded areadiscussed above is used for field planted material to compliment themodular system. In this instance, the membrane 54A is perforated at 88for drainage, and is lined with anti-root fabric 150 to prohibit growthof roots through the membrane and into the waterways provided on theroof deck. Rather than rounded stone, the membrane shown is supported onand the waterways of the roof are provided by a molded plastic sheet 152having spaced frusto-conical supports provided with additional drainholes 154.

With suitable edge finishing, the green roof system can be arranged toprovide for other, either fully or partially enclosed areas on the roofdeck for other uses and purposes. Advantageously, this arrangement issuitable for use in combination with installed green roof systems ofprior designs. As a result, the modular green roof systems of thepresent invention can be used as a replacement for portions of priorsystems such as in the event a portion of the prior green roof isremoved for repair of the underlying roof structure. Partially enclosedareas may also include the irregular edge areas of the roof deck.

Support Framework for Additional Decorative and Functional Add-onStructures

Preferred green roof systems hereof are also provided with a supportframework, structure or anchoring system to support add-on componentssuitable for use for decorative and/or functional purposes to complimentthe modular and non-modular aspects of the green roof system.

Additional or add-on components may be temporary structures such asmaintenance walkways or apparatus to assist in installation or removalof filled panels, or they may be semi-permanent structures such asbridges 84 (FIG. 27), trellises, sun shades, sun or weather typegazebos, fabric canopies 72 (FIG. 26) and other desired above-panelstructures that are maintained in the installed green roof system.

In carrying out this aspect of the invention, one embodiment of asuitable framework or support structure is provided by the dimensionallumber/composite extrusion edge joining system described above. In thisinstance, the lumber or extrusion 46 is connected under panel flanges(e.g., 26, 26A) as necessary for support of the desired additionalstructures, with the structures being secured to the edge framework asrequired.

Alternately, for example, the support framework includes spaced supportplates molded in or secured to the top section of the panels, or securedto the support lumber/extrusion 46 if used therewith, the support platesbeing adapted for cooperation with the add-on components to providesupport thereof. In the embodiment shown in FIG. 16, support plates inthe form of corner gussets 60 are provided with vertically extendingopenings 62 sized to receive support poles 70 of the add-on components.

Roof Deck and Green Roof Maintenance and Repair

Advantageously, green roof systems of the present invention are uniquelyadapted for ease of maintenance and repair of both the green roof systemitself and the underlying roof deck structure.

Bridge Access/Walkway Panels

As illustrated in FIGS. 17 and 18, in green roof systems that includeintermediate boundary, panel edge support systems such as thedimensional lumber/composite extrusion edge systems described above,access to the planted areas is provided using the strength of the paneledge support system with a bridge or plank 150, or other bridgingmechanism (see e.g., FIG. 27) that is laid over the modular panels andsupported by the panel edge support system. The walkways or bridges mayinclude provision to maintain alignment on the panels such as withbrackets 152 (FIG. 18). Such walkways can be temporary or permanent toprovide walkways for elevated access to the planted areas withoutdisturbing them.

Movement of Filled Panels

In accordance with another aspect of the invention, apparatus isprovided for lifting and moving individual filled panels, forinstallation of the green roof system with pre-seeded or pre-plantedpanels, and for lifting, removing and replacing individual filled panelsfrom an installed green roof, without the need to disturb surroundingpanels.

Advantageously, such a non-progressive arrangement, i.e., the ability tolift and move panels from the installed green roof without the need todisturb adjacent panels, permits access to portions of the underlyingroof deck such as for repair or periodic maintenance or access to drainopenings without the need to tear-up and destroy large sections of thegreen roof as with prior green roof systems, and provides the ability tochange the green roof design after its initial installation by simplyrearranging or replacing desired panels.

More particularly, the modular panels are adapted to connect to andcooperate with an above-panel support and transport framework forlifting and moving thereof.

Panel Lifting and Moving Apparatus

In carrying out this aspect of the invention, the modular panels areprovided with grabbing or gripping apparatus adapted to facilitate beinglifted vertically upwardly so as to not disturb adjacent panels.

In one embodiment, the panels are provided with lifting hooks, handles,openings or like structure or devices sized to connect to or receive anextension member adapted to extend upwardly to the above-roof supportframework.

The extension member can be either a flexible member such as a strap,rope, cable or like carrying and support apparatus, a rigid extensionmember, a jointed rigid member, or a combination thereof such that themember is adapted for connection between the panels and the above-roofsupport framework and to lift and support the panels therefrom.

In the embodiment shown in FIGS. 1, 20 and 21, the panels 10 areprovided with relatively deep grooves 30 formed extending along thebottom of the panel 10, and a flexible cable or strap 80 extendsunderneath the panel through the grooves. The top of the strap isprovided with eyelets 82, hooks or other apparatus suitable forconnecting to the above-roof support framework. Such straps or cablescan either be permanently positioned under the panels before they areinstalled onto the roof deck, or fed through the groove prior to liftingthe panel. Thus, the filled modular panels can, among other things, belifted out of the field for access to roof deck in the surrounded areasuch as indicated at 86 in FIG. 22. Alternately, enclosed grooves ortunnels can be formed along the bottom and extending up the sides of themodular panels to facilitate threading the lifting strap therethrough.

Optional spreader bars 84 are installed across the top of the panels,connected between opposite sides of the panel, and generally alignedwith the straps 80, prior to lifting or transport of the panels. Thespreader bars prevent the panel from collapsing inwardly onto itself dueto the weight of the fill in the panel in the event the design of thepanel presents such a possibility. For smaller panels, the spreader baris also sized to carry the weight of the panel such that the panels canbe manually carried with the bar attached.

Supporting Framework

The above-roof framework includes apparatus for connecting to theextension members, lowering and raising the panels after connectionthereto, and transporting the panels from one location to another on theroof.

FIG. 23 illustrates a framework 90 comprising vertical legs 92 supportedwith feet 94 and/or in stationary support brackets such as brackets 60,top rails 96 supported on the legs 92, cross-beams 98 releasablyconnected at 100 to the straps 80, and apparatus for raising andlowering the filled panels and sliding or rolling the raised panelsalong the rails 96 for repositioning as indicated by arrow A-A.

FIG. 24 illustrates the support rails 98 slipped through the loops 82such as for use in the rail system of FIG. 23, or simply comprising analternate framework of spaced parallel rails for manually raising andcarrying the filled panels.

FIG. 25 illustrates another alternate framework 104 with castors orwheels to assist in transporting the filled panels. With sucharrangement, the rails 98 may be adapted for manually raising the paneland then connection to the framework, or the rails may be permanentlyconnected, with panel raising and lowering apparatus, and with thewheels adapted for rolling in grooves such as formed in the top of thelumber/extrusion edge support systems discussed above.

Advantageously, such arrangements for lifting and moving filled panelsprovides for freedom of design of the entire green roof system,including being able to install the green roof system without coveringor enclosing the entire roof deck area with a fully seeded or plantedarea of prior green roof systems, allowing the design of the installedgreen roof system to be changed as required or desired, and to be ableto cooperate with prior green roof systems so as to provide fully seededand planted area(s) of prior systems in combination with areas of themodular system hereof such as interspaced therewith or around theperimeter.

Pre-Seeding of Modular Panels

In accordance with yet another aspect of the invention, the modularpanels 10 are pre-filled with suitable growing medium 110 (see e.g.,FIG. 29) and pre-planted with sedum, shrubbery, perennials, foliageand/or other green roof vegetation or plants 112 in accordance with oneof several alternate methods, or alternately pre-filled with non-growingdecorative materials.

In the case of plant materials, the panels are either pre-planted andthen suitably preserved until shipped for installation into a green roofsystem, or pre-planted, germinated, and maintained in a growingcondition until needed.

Advantageously, pre-planted preserved panels can be prepare well inadvance of when they will be needed, and then stocked and maintained ina preserved condition for as long as desired. This permits additionalselection and quantities of green roof materials to be available duringthe green roof installation season without concern for spoilage sinceunused preserved panels can be simply maintained until the next season.

To obtain pre-planted panels in a preserved state, ready forinstallation, the panels are filled with sanitized dry earth or othersuitable growing medium 114, pre-seeded with sedum or other perennialseed, and maintained in a dry state to preclude germination.

Alternately, for example, the plants in the panels may be germinated andpre-grown in a greenhouse, and as they reach the appropriate growth forthe geographic area in which they are to be located, and frozen as wouldoccur during the normal winter cycle for perennials of such type. Thefrozen pre-grown panels are then cryogenically preserved until shippedfor installation into a green roof system.

Cryogenically preserving pre-grown panels offers the unique ability tostock a selection of “ready to grow” materials without the need tomaintain growing plants and the expense associated therewith. Thus, agreater selection can be prepared in advance, without concern foradditional costs of maintenance or spoilage if not used within aspecific time period.

Advantageously, the growing medium used in the modular panels may alsoinclude the same types of materials used in prior green roof systemssuch as pre-cut mats of mineral wool or water retention substrate, andpre-cut mats of pre-seeded fiber fleece. Thus, manufacturers andsuppliers or prior green roof systems are able to also supply andrealize the benefits of modular green roof systems in accordanceherewith using many of the same materials.

Storage of Pre-Planted Modular Panels

In keeping with the invention, the pre-planted panels 10 are stored in amanner suitable for preserving the plants therein.

For example, pre-planted pre-growing panels can be stored in agreenhouse, maintaining the growing condition of the plants untilshipped to an installation site. Such storage can be provided onshelves, or if provided with covers suitable to permit exposure tolight, watering and air circulation, the panels can be stored in stacks.

In the case of pre-planted panels that are preserved in a non-growingstate, the panels are optionally sealed by vacuum packing, with acomplete vacuum liner 120 (FIG. 29) such as of approximately 6-8 milthickness surrounding the entire panel. This vacuum packed package 122is then either dry or cryogenically preserved to prohibit any or furthergrowth, and to protect from contamination, moisture, and sunlight (ifprovided with a sun-blocking film). The panels are then maintained readyfor shipment and placement as desired at the job site with an assuredpre-seeded type of foliage or growth that would match and be identifiedby alphanumeric characteristics such as generally indicated by the pairsof numbers shown in FIG. 1. The advantages of such pre-planting andpre-packaging includes the simplicity and freedom of green roof systemdesign. And the cryogenically preserved panels assure growth within arelatively short time assuming the green roof is installed during thewarmer months.

Shipping of Pre-Planted Modular Panels

The pre-seeded panels are also adapted for ease of shipment to theinstallation site with provision of covering, stacking and banding thestacked panels together.

To this end, and if not provided previously such as for purposes ofstorage, stacking for shipment may be provided for with a rigid cover orseparator 130 such as made from a plywood board, rigid compositeextrusion or other suitable rigid material, pre-cut to size, and placedover the panels (see FIG. 29). An edge extrusion 132, shaped and sizedfor cooperation between the upper portion of the lower panel and/or itscover (e.g. 130), and the lower portion of the adjacent upper panel, issecure between the stacked panels to prevent the panels from slippingrelative to one another. This allows the panels to be stacked andsecured or banded together for shipping. Alternately, a molded rigidcover may be provided with an integrally molded edge extension, orintegrally molded pattern configured to interlock with, for example, thegrooves 30 or the waffle design of the bottom of the panel stackedthereon.

Shipping of panels with plants or other items that extend above the topof the panel 10 requires the use of a rigid cover with a “bubble” sizedto protect the plants during shipment. FIG. 30 illustrates oneparticularly advantageous arrangement for preparing such pre-plantedpanels for shipment. In this instance, the shipping lid is an emptypanel 10 which is turned upside down onto the filled panel, with theedges of the panels temporarily secured together as indicated at 138.Also shown in FIG. 30 is a rigid separator board 140 between the stackedpanels with an edge extrusion 142 fastened to secure the stacked panelsfrom sliding during shipment. Alternately, in contemplation of usingempty panels as shown to protect contents of filled panels, the lowerportions of the panels are molded with connector receiving indentationsor openings adapted for receiving temporary shipping connectors thatwould secure the “top” of an inverted panel with the bottom of theupright panel stacked thereon. In view of the disclosure hereof, thoseskilled in the art will appreciate numerous variations and other methodssuitable for use in pre-filling, planting, and otherwise preparing themodular panels for use in green roof systems according to the invention.

From the foregoing, it will be apparent that the present inventionbrings to the art new and improved green roof system and associatedmethods, including uniquely configured interlocking modular panels andassociated apparatus for use therewith.

1. A modular green roof system comprising: a plurality of generallyrectangular panels resting on a roof in side by side relation to cover aclosed space on the roof, each panel having a bottom and sides extendingupwardly therefrom to define a surrounded space for green roofmaterials, the bottoms of the panels being formed with drain holes andhaving an underside configured to permit water to flow thereunder alongthe roof, the sides of the panels having surrounding flanges in side byside relation with flanges of adjacent panels, the flanges having anunderside, and connector strips overlaying the flanges of adjacentpanels, and connectors installed through the connector strips from abovethe panels and engaging the underside of the flanges for releasablyconnecting the connector strips and flanges of adjacent panels together.2. The green roof system of claim 1 in which said connector strips arepositionable and removable from above the panels.
 3. The green roofsystem of claim 1 in which said panels are supplied pre-seeded with thegreen roof materials.
 4. The green roof system of claim 3 in which saidpre-seeded panels are supplied in a pre-growing condition.
 5. The greenroof system of claim 3 in which said pre-seeded panels are supplied in apreserved condition.
 6. A modular green roof system comprising: aplurality of generally rectangular panels positioned in side by siderelation on a roof, each panel having a bottom and sides extendingupwardly therefrom to define a surrounded space for green roofmaterials, the bottoms of the panels being formed with drain holes andhaving an underside configured to permit water to flow thereunder alongthe roof, the sides of the panels being in side by side relation withsides of adjacent panels, and elongated connector strips releasablyconnected in position over adjacent sides of adjacent panels andcooperating to cover the sides of adjacent panels, and connectorsinstalled from above through the connector strips for releasablyconnecting the connector strips and sides of adjacent panels together.